An apparatus for additive manufacturing of a high temperature alloy powder production and methods of use thereof

Abstract

The application discloses a kind of high-temperature alloy powder production device of additive manufacturing and its use method, it is related to metal powder production field, including smelting structure and atomization structure, the smelting structure includes furnace cover, furnace cover top is equipped with lifting structure, furnace cover bottom is equipped with smelting furnace, and smelting furnace is installed with atomization structure;The atomization structure includes main nozzle, and the main nozzle is fixedly connected at the center point of furnace cover, and there are adjusting nozzle in the annular array around main nozzle, camera is equipped between smelting furnace and furnace cover, and camera is installed on moving support.Compared with prior art, the advantages of the present application are that: the automation adjustment of furnace cover lifting is realized by telescopic cylinder, the risk of manual operation is completely eliminated, the safety performance is significantly improved, the assembly process is simplified and the reliability is enhanced, the efficient composite atomization is realized by inert gas, the droplet formation and spheroidizing effect are accurately optimized, and the powder characteristics are optimized by dynamically adjusting nozzle parameters.

Description

Technical Field

[0001] This application relates to the field of metal powder production, and more particularly to an additive manufacturing apparatus for producing high-temperature alloy powder and its method of use. Background Technology

[0002] With the rapid development of additive manufacturing (AM) technology, high-temperature alloy powders, as core raw materials for high-performance components, are increasingly in demand in aerospace, energy, and other fields. Gas atomization (GA) technology, as the mainstream method for preparing high-temperature alloy powders, uses high-pressure inert gas to break up molten metal flow into micron-sized particles and has already achieved industrial application. In recent years, this technology has made significant progress in nozzle design, melting chamber sealing, and process parameter optimization, such as using multi-nozzle array structures to improve atomization uniformity or introducing vacuum systems to reduce oxygen content. However, existing devices generally rely on static melting and atomization parameter settings, making it difficult to adapt to the dynamic flow characteristics of different alloy melts, resulting in insufficient powder quality stability. At the same time, the weak control of the airtightness of the melting chamber and the weak real-time process monitoring capabilities restrict the precise control of key indicators such as powder sphericity, particle size distribution, and oxygen content, making it difficult to meet the stringent requirements of high-end additive manufacturing for powder performance.

[0003] Existing technologies have shortcomings in terms of dynamic adaptability and process controllability. First, the relative positions of the melting furnace and the atomizing nozzle are fixed and cannot be dynamically adjusted, leading to an imbalance in the atomizing cone angle and an expansion of the powder particle size distribution range. Second, the lack of real-time monitoring methods for the molten pool state causes instability in the liquid flow or insufficient atomization, resulting in powder agglomeration or accelerated oxidation. These deficiencies directly limit the stable mass production of powders with high sphericity and low oxygen content, becoming a key bottleneck restricting breakthroughs in high-temperature alloy additive manufacturing processes. Summary of the Invention

[0004] This application provides a high-temperature alloy powder production apparatus for additive manufacturing and its usage method, which solves the problems of low powder sphericity, high oxygen content and wide particle size distribution in existing gas atomization technology.

[0005] This application provides a high-temperature alloy powder production device for additive manufacturing and its usage method, including a melting structure and an atomizing structure. The melting structure includes a furnace cover, a lifting structure at the top of the furnace cover, a melting furnace at the bottom of the furnace cover, and an atomizing structure installed on the melting furnace. The atomizing structure includes a main nozzle, which is fixedly connected to the center point of the furnace cover. Adjustable nozzles are arranged in a ring around the main nozzle. A camera is provided between the smelting furnace and the furnace cover, and the camera is mounted on a movable bracket.

[0006] As an improvement, the lifting structure consists of two telescopic cylinders, which are symmetrically arranged on the central axis of the furnace cover. The telescopic cylinders are electrically adjustable, reducing the number of manual operation steps and improving safety performance.

[0007] As an improvement, the inner ring of the smelting furnace and the outer ring of the furnace cover are fitted with a clearance fit, and a sealing ring is provided at the fit. The sealing ring is a beveled metal protrusion. The clearance fit and the beveled protrusion form a seal while facilitating docking. The beveled protrusion has a certain guiding function. The use of metal material is to prevent the sealing ring from melting due to the high temperature inside the smelting furnace.

[0008] As an improvement, the main nozzle is larger than the regulating nozzle. Both the main nozzle and the regulating nozzle are connected to a gas tank via pipelines. The gas tank contains inert gas, which is the gas required in the metal powder production process. The gas tank is pressurized by an air pump and then sprayed out through the nozzle.

[0009] As an improvement, the adjusting nozzle is rotatably connected to the smelting furnace, and a connecting ring is provided at the connection point. An arc-shaped groove is provided at the connection point between the adjusting nozzle and the connecting ring. The cooperation between the arc-shaped groove and the connecting pipe ensures that the adjusting nozzle can rotate at the connection point, which ensures the adjustability of the nozzle.

[0010] As an improvement, an adjusting arm is fitted onto the adjusting nozzle. The adjusting arm is a pneumatic adjusting arm, which is mounted on a transverse adjusting cylinder. Through transverse and longitudinal adjustment, the rear section of the adjusting nozzle is moved and rotated under the action of the connecting ring.

[0011] As an improvement, the end of the adjusting arm is installed in the adjusting groove, the adjusting groove is fixedly connected to the fixed plate, and a transverse adjusting cylinder is installed on the fixed plate to limit the movement of the adjusting arm and ensure that its movement range is within the adjusting groove.

[0012] As an improvement, a flexible pad is provided at the connection between the adjusting arm and the adjusting nozzle. The function of the flexible pad is to ensure the adjustability of the adjusting nozzle.

[0013] As an improvement, the movable support is a telescopic cylinder, and a camera bracket is installed on the movable support. The camera is an industrial high-temperature resistant camera, which allows for observation of the smelting process, avoiding manual confirmation.

[0014] As an improvement, the usage steps are as follows: S1. Load the proportioned high-temperature alloy raw materials into the melting furnace, close the furnace cover, and ensure the airtightness of the melting chamber through the sealing ring; S2. Start the vacuum system to evacuate the melting chamber to ≤10°C. -2 Pa, then an inert gas is introduced as a protective atmosphere; S3. Start the induction heating system to melt the high-temperature alloy raw materials into a uniform liquid metal in the melting furnace, and control the melting temperature between 1450 and 1650℃. S4. Adjust the relative position between the furnace cover and the smelting furnace by means of the lifting structure; S5. Simultaneously open the main nozzle and multiple adjusting nozzles arranged in a ring array, and introduce inert gas at a pressure of 0.8 to 1.8 MPa to perform composite atomization on the molten metal flow from the melting furnace, forming atomized spherical droplets. S6. The system monitors the molten pool status, liquid flow stability and atomization process in real time using a camera and a mobile support, and dynamically adjusts the gas flow rate, angle and position of the main nozzle and the regulating nozzle based on the image feedback. S7. Use the horizontal adjustment cylinder to drive the adjustment arm, which in turn drives the adjustment nozzle to rotate around the connecting ring, adjusting its spray direction and tilt angle, and optimizing the atomization cone angle and powder particle size distribution. S8. The atomized droplets cool and solidify in the inert atmosphere protection chamber and fall to the bottom of the furnace to obtain high-temperature alloy powder with a particle size range of 15-105μm, sphericity ≥90%, and oxygen content ≤60ppm.

[0015] Compared with existing technologies, the advantages of this invention are as follows: The automated adjustment of the furnace cover's lifting and lowering is achieved through a telescopic cylinder, completely eliminating the risks of manual operation and significantly improving safety performance; the beveled metal sealing ring between the smelting furnace and the furnace cover maintains excellent airtightness under high-temperature conditions, simplifying the assembly process and enhancing reliability. The main nozzle and the annular adjusting nozzle work together, in conjunction with inert gas, to achieve efficient composite atomization, precisely optimizing droplet formation and spheroidization effects. An integrated industrial high-temperature resistant camera mobile support system monitors the molten pool status and atomization process in real time, dynamically adjusting nozzle parameters to optimize powder characteristics. The overall design effectively improves the sphericity, particle size uniformity, and oxygen content control of the powder, significantly improving powder quality and production efficiency, while ensuring process stability and ease of operation. Attached Figure Description

[0016] The accompanying drawings are provided to further understand the technical solutions of the present invention and constitute a part of the specification. They are used together with the embodiments of this application to explain the technical solutions of the present invention and do not constitute a limitation on the technical solutions of the present invention.

[0017] Figure 1 Structural schematic diagrams provided for embodiments of this application; Figure 2 A perspective view provided for an embodiment of this application; Figure 3 A front view provided for embodiments of this application; Figure 4 A side view provided for an embodiment of this application; Figure 5A cross-sectional view of section AA provided for an embodiment of this application; Figure 6 An enlarged view of the structure of region B provided for an embodiment of this application; Figure 7 An enlarged view of the C-region structure provided for an embodiment of this application; Figure 8 An enlarged view of the D-region structure provided for an embodiment of this application; Figure 9 A schematic diagram of the adjustment groove structure provided in an embodiment of this application.

[0018] The components are as follows: 1. Smelting structure; 11. Furnace cover; 111. Sealing ring; 12. Lifting structure; 121. Telescopic cylinder; 13. Smelting furnace; 131. Connecting ring; 2. Atomizing structure; 21. Main nozzle; 22. Adjusting nozzle; 221. Arc groove; 222. Adjusting arm; 223. Lateral adjusting cylinder; 224. Adjusting groove; 225. Fixing plate; 226. Flexible pad; 23. Camera; 24. Moving bracket; 241. Camera bracket. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0020] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0021] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0022] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "connected" and "linked" should be interpreted broadly, for example, as a fixed connection, a detachable connection, or an integral connection. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances. Furthermore, when describing pipelines, the terms "connected" and "linked" as used in this application have the meaning of establishing electrical connection. The specific meaning needs to be understood in conjunction with the context.

[0023] In the embodiments of this application, the terms "exemplary" or "for example" are used to indicate that something is an example, illustration, or description. Any embodiment or design that is described as "exemplary" or "for example" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or design. Specifically, the use of the terms "exemplary" or "for example" is intended to present the relevant concepts in a specific manner.

[0024] like Figures 1-9 A high-temperature alloy powder production device for additive manufacturing and its usage method, comprising a melting structure 1 and an atomizing structure 2, wherein the melting structure 1 includes a furnace cover 11, a lifting structure 12 is provided at the top of the furnace cover 11, a melting furnace 13 is provided at the bottom of the furnace cover 11, and an atomizing structure 2 is installed on the melting furnace 13. The atomizing structure 2 includes a main nozzle 21, which is fixedly connected to the center point of the smelting furnace 13. Adjustable nozzles 22 are arranged in a ring around the main nozzle 21. A camera 23 is provided between the smelting furnace 13 and the furnace cover 11, and the camera 23 is mounted on a movable bracket 24.

[0025] Place the proportioned raw materials into the melting furnace 13 and close the furnace lid 11; evacuate to a vacuum level of ≤10. -2 After Pa, high-purity inert gas is introduced; induction heating is carried out to 1450–1650℃ to form a uniform melt; the lifting structure 12 finely adjusts the position of the furnace cover to ensure docking accuracy; the main nozzle 21 and the annular array adjusting nozzle 22 are opened, and the high-pressure gas performs composite impact atomization on the falling molten metal; the moving bracket 24 drives the industrial high-temperature resistant camera 23 to scan along the vertical direction, capturing the molten pool shape, liquid flow stability and atomization cone dynamic images in real time, and the data is fed back to the control system.

[0026] The main nozzle and the regulating nozzle work together to construct a three-dimensional controllable airflow field, precisely controlling the Weber number and Stokes number, significantly narrowing the particle size distribution, making D90 / D10≤1.5, improving sphericity to ≥95%, and suppressing satellite powder generation; dynamic monitoring by camera combined with parameter feedback realizes "visualized-intelligent" closed-loop control of the atomization process, enhancing process repeatability and powder batch consistency, reducing oxygen content to ≤60ppm, which meets the core requirements of additive manufacturing for high powder flowability and low defect rate.

[0027] The lifting structure 12 consists of two telescopic cylinders 121, symmetrically positioned on the central axis of the furnace cover 11. Electric adjustment via these cylinders reduces manual operation steps and improves safety. Both cylinders 121 are driven by the same servo control system, ensuring strictly synchronized extension and retraction. This eliminates the risk of uneven load on the furnace cover, guarantees concentricity and sealing reliability, avoids sealing failure or mechanical jamming due to tilting, and enhances the safety of automated operation.

[0028] The inner ring of the smelting furnace 13 and the outer ring of the furnace cover 11 are fitted with a clearance. A sealing ring 111 is provided at the fitting point. The sealing ring 111 is a beveled metal protrusion. The clearance fit and the beveled protrusion form a seal while facilitating docking. The beveled protrusion has a certain guiding function. The use of metal material is to prevent the sealing ring from melting due to the high temperature inside the smelting furnace.

[0029] The main nozzle 21 is larger than the adjusting nozzle 22. Both the main nozzle 21 and the adjusting nozzle 22 are connected to a gas tank via pipelines. The gas tank contains inert gas, which is required in the metal powder production process. The gas tank is pressurized by a gas pump and then ejected through the main nozzle. The inert gas used is high-purity argon (Ar, ≥99.999%). Argon is chemically inert and isolates oxygen / nitrogen, while its high density enhances the flow rate. Based on Rayleigh-Taylor instability, the supersonic airflow impacts the liquid flow, causing it to break into microdroplets, while simultaneously inhibiting oxidation reactions. The oxygen content of the powder is stably ≤60ppm, and the sphericity is improved to ≥95%, ensuring the density and high-temperature mechanical properties of the subsequently SLM formed parts.

[0030] The regulating nozzle 22 is rotatably connected to the melting furnace 13, with a connecting ring 131 at the connection point. An arc-shaped groove 221 is provided at the connection between the regulating nozzle 22 and the connecting ring 131. The cooperation between the arc-shaped groove and the connecting pipe ensures that the regulating nozzle can rotate at the connection point, guaranteeing its adjustability. The main / regulating nozzle is connected to a pressurized gas tank via a high-temperature resistant pipeline, and gas is injected into the bottom of the melting furnace 13 through the nozzle. The regulating nozzle 22 achieves ±15° tilt angle adjustment through the hinge structure of the connecting ring 131 and the arc-shaped groove 221, dynamically optimizing the atomization cone angle and the gas flow intersection point. Adapting to different alloy surface tension / viscosity parameters, the yield of powder with a target particle size of 15–53 μm is increased to over 85%, significantly improving powder spreading uniformity and molten pool stability.

[0031] An adjusting arm 222 is fitted onto the adjusting nozzle 22. The adjusting arm 222 is a pneumatic adjusting arm, which is mounted on a transverse adjusting cylinder 223. Through transverse and longitudinal adjustment, it drives the rear section of the adjusting nozzle to move and rotate under the action of the connecting ring. The transverse adjusting cylinder 223 pushes the adjusting arm 222 to move laterally along the adjusting groove 224 on the fixed plate 225. The displacement is transmitted to the rear section of the adjusting nozzle 22 via the flexible pad 226. Combined with the rotating pair of the connecting ring 131 and the arc-shaped groove 221, the linear motion is converted into angular adjustment around the axis of the connecting ring. The moving bracket 24 independently controls the displacement of the camera 23. The flexible pad 226 absorbs thermal deformation and assembly tolerances, ensuring smooth adjustment and sealing integrity.

[0032] The end of the adjusting arm 222 is installed in the adjusting groove 224, which is fixedly connected to the fixing plate 225. A transverse adjusting cylinder 223 is installed on the fixing plate 225 to limit the movement of the adjusting arm and ensure that its movement range is within the adjusting groove.

[0033] A flexible pad 226 is provided at the connection between the adjusting arm 222 and the adjusting nozzle 22. The function of the flexible pad is to ensure the adjustability of the adjusting nozzle.

[0034] The movable support 24 is a telescopic cylinder, and a camera bracket 241 is mounted on it. The camera 23 is an industrial high-temperature resistant camera, allowing observation of the smelting process through a movable industrial camera, thus avoiding manual verification. The movable support 24 drives the camera 23 to move back and forth along a preset trajectory, acquiring images of molten pool fluctuations and liquid flow deviations in real time. The system uses image recognition algorithms to detect anomalies and automatically activates the lateral adjustment cylinder 223 to adjust the nozzle angle or regulate the gas flow rate. Technical effect: Constructing a closed loop of "visual perception - parameter feedback - dynamic correction" reduces the risk of manual intervention and improves process robustness and powder quality consistency.

[0035] The usage steps are as follows: S1. Load the proportioned high-temperature alloy raw materials into the melting furnace 13, close the furnace cover 11, and ensure the airtightness of the melting chamber through the sealing ring. S2. Start the vacuum system to evacuate the melting chamber to ≤10-2Pa, and then introduce high-purity inert gas as a protective atmosphere. S3. Start the induction heating system to melt the high-temperature alloy raw material into a uniform liquid metal in the melting furnace 13, and control the melting temperature at 1450-1650℃. S4. Adjust the relative position between the furnace cover 11 and the smelting furnace 13 by means of the lifting structure 12; S5. Simultaneously open the main nozzle 21 and multiple annular array-arranged regulating nozzles 22, and introduce high-pressure inert gas at a pressure of 0.8 to 1.8 MPa to perform composite atomization on the molten metal flow from the melting furnace 13, forming fine droplets with high sphericity. S6. The camera 23, together with the mobile support 24, monitors the molten pool status, liquid flow stability and atomization process in real time, and dynamically adjusts the gas flow rate, angle and position of the main nozzle 21 and the regulating nozzle 22 based on the image feedback. S7. Use the transverse adjustment cylinder 223 to drive the adjustment arm 222, which in turn drives the adjustment nozzle 22 to rotate around the connecting ring 131, adjusting its spray direction and tilt angle, and optimizing the atomization cone angle and powder particle size distribution. S8. The atomized droplets cool and solidify in the inert atmosphere protection chamber and fall to the bottom of the furnace to obtain high-temperature alloy powder with a particle size range of 15-105μm, sphericity ≥90%, and oxygen content ≤60ppm.

[0036] Example: This embodiment details the overall workflow and working principle of a high-temperature alloy powder production device for additive manufacturing, ensuring that examiners can accurately manufacture the equipment based on this embodiment. The overall layout of the equipment is as follows: the melting structure 1 consists of a furnace cover 11, a lifting structure 12, and a melting furnace 13; the atomization structure 2 includes a main nozzle 21, an adjusting nozzle 22, a camera 23, and a moving support 24. Each component is precisely configured according to the reference numerals in the claims, and the specific workflow is as follows: 1. Initial equipment assembly and raw material loading First, the furnace cover 11 is placed on top of the melting furnace 13. The inner ring of the melting furnace 13 and the outer ring of the furnace cover 11 are fitted with a clearance of 0.1–0.3 mm. A sealing ring 111 is embedded at the fit—this sealing ring is a beveled metal protrusion made of 304 stainless steel with a bevel angle of 30° to ensure that it does not melt at 1650°C and forms a reliable seal. Then, the prepared high-temperature alloy raw material, such as IN718 alloy powder with a particle size <50 μm, is loaded into the melting furnace 13. After the furnace cover 11 is closed, the sealing ring 111 undergoes elastic deformation under the pressure of the furnace cover 11. The beveled guiding structure makes the connection smoother, and the airtightness reaches ≤10. -3 Pa.

[0037] 2. Vacuum treatment and smelting start-up Start the vacuum system, model: Pfeiffer Vacuum Turbo 150, and evacuate the melting chamber to ≤10. - 2The system integrates a pressure sensor, model: Pfeiffer Vacuum PKR 251. Its real-time pressure signal is transmitted to the PLC control system, model: Siemens S7-1500 CPU 1515F, via shielded twisted-pair cable. Once the vacuum level is reached, the PLC outputs a digital signal to control the argon solenoid valve, model: SMC VQ5000, to open, introducing high-purity argon gas (≥99.999% purity) at a pressure of 0.1 MPa as a protective atmosphere. The induction heating system, model: Leybold Induction Heater 50 kW, is started synchronously. Its water-cooled induction coil surrounds the outer wall of the melting furnace 13. After being energized, it generates an alternating magnetic field to achieve induction melting of the raw materials. The system has a built-in K-type armored thermocouple, model: Omega Engineering KMQSS-125U, with a temperature measurement range of 0~1800℃. The analog signal of the melt temperature of 4~20 mA is transmitted to the PLC through a signal isolation module, model: Weidmüller ACT20M. The PLC adjusts the output power of the thyristor power regulator, model: Eurotherm 1000, according to the preset temperature curve through the PROFIBUS-DP protocol to achieve precise temperature control of ±5℃. During the smelting process, the lifting structure 12 remains stationary. Its two telescopic cylinders 121 (SMC SH25-50A, with built-in magnetostrictive displacement sensors (MTS Temposonics RHM0500)) feed back the real-time position signal of the furnace cover 11 to the PLC. The PLC dynamically compensates for cylinder pressure fluctuations through a proportional pressure valve (SMC ITV3050) to ensure that the relative position deviation between the smelting furnace 13 and the furnace cover 11 is ≤ ±0.1 mm. All subsystems are connected to the PLC via an industrial Ethernet closed-loop control network. Control commands and feedback signals are transmitted through shielded cables. The anti-interference design complies with the GB / T 17626 electromagnetic compatibility standard, providing a stable and clean melt foundation for the subsequent atomization stage.

[0038] 3. Atomization Start A precision guide outlet is located at the center of the bottom of the melting furnace 13, through which molten metal flows vertically downward to form a stable liquid column. The main nozzle 21 is rigidly fixed to the mounting base at the center of the bottom of the melting furnace 13 by an M16×1.5 thread. The nozzle end face is 5.0±0.2mm away from the guide outlet end face, and the jet axis is strictly coincident with the molten metal flow axis. 1.2 MPa high-pressure argon gas is injected axially upward to form a central main airflow that opposes the liquid flow. Six adjustable nozzles 22Φ4mm, Hastelloy C-276, are mounted in a ring array around the guide outlet via connecting rings 131. The connecting rings 131 are fastened to the ring mounting surface at the bottom of the melting furnace 13 with M6×12 bolts. The tail of the adjustable nozzle 22 is embedded in the mounting hole of the connecting ring 131. Its outer wall arc-shaped groove 221, with a radius of 5mm, is precisely matched with the guide pin embedded in the connecting ring 131, limiting the adjustable nozzle 22 to rotate smoothly within a range of ±30° around the central axis of the connecting ring 131. In the initial state, the nozzle end face of each adjusting nozzle 22 is 8.0±0.3mm away from the guide outlet end face, the jet axis forms a 45° angle with the vertical liquid flow axis, and the six lateral airflows are precisely converged at the atomization focal point 10mm above the main nozzle 21.

[0039] The gas pipeline system adopts dual-loop independent control: the main nozzle 21 and the regulating nozzle 22 are respectively connected to the gas tank, Linde Gas Cylinder 10L, via high-pressure metal hoses, Swagelok SS-43S, inner diameter Φ6mm; the pipeline integrates a mass flow controller, Bronkhorst EL-FLOW Select F-201CV, range 0~50 L / min, and a pressure sensor, WIKA A-10, 0~2.5 MPa, and the signal is transmitted to the PLC control system, Siemens S7-1500, in real time. When atomization starts, the PLC dynamically adjusts the flow based on the liquid diameter feedback from camera 23: the gas flow rate of the main nozzle 21 is set to 35 L / min to axially impact and break the root of the liquid column; the single-channel flow rate of the adjusting nozzle 22 is set to 12 L / min to laterally shear and refine the droplets. When the liquid flow deviates, the PLC drives the lateral adjusting cylinder 223, and the SMC SC16-100A pushes the adjusting arm 222, which, through the silicone flexible pad 22, drives the adjusting nozzle 22 to finely adjust the tilt angle by ±5°, so that the six lateral airflows re-converge precisely at the atomization focus. This composite airflow field efficiently breaks the molten metal into 10-50 μm droplets. High-speed camera verification shows that the atomization cone angle is stable at 60°±3°, laying a fluid dynamics foundation for obtaining highly spherical powders.

[0040] 4. Real-time monitoring and dynamic nozzle adjustment Camera 23, model BasleraceacA2440-20uc, is an industrial high-temperature resistant camera with an operating temperature of -20 to 200℃. It is mounted on camera bracket 241. The movable bracket 24, model SMCSH20-30A, uses a telescopic cylinder to drive the camera 23's horizontal / vertical movement within a ±100mm range, capturing real-time images of the melting chamber. Image data is transmitted to the control terminal, and the system automatically adjusts based on the molten pool temperature (1500±20℃) and the stability of the liquid flow. The horizontal adjustment cylinder 223, model: SMCSC16-100A, drives the pneumatic adjustment arm 222, which is made of polyurethane. The end of the adjustment arm 222 is embedded in the adjustment groove 224 and fixed to the fixed plate 225, thereby achieving a horizontal displacement of ±20mm for the adjustment nozzle 22. A flexible pad 226 made of silicone with a thickness of 2mm is provided at the connection between the adjusting arm 222 and the adjusting nozzle 22 to ensure that the rotation is smooth and free from jamming. Adjust the nozzle 22 to rotate around the axis under the drive of the connecting ring 131, adjust the spray angle from 0 to 45°, optimize the atomization cone angle to 60°±5°, so that the powder particle size distribution is concentrated in the range of 50 to 150 μm.

[0041] 5. Powder collection and quality control The atomized molten metal droplets rapidly cool and solidify in an inert atmosphere at a cooling rate ≥10. 4 The powder, collected at a rate of K / s, is processed by a powder collection system including a cyclone separator and a sieving device. After sieving through a 105μm sieve, the particle size ranges from 15 to 105μm, with sphericity ≥90% analyzed using ImageJ software. Oxygen content ≤60ppm is detected using a LECOTC-600 analyzer. The final powder is directly used in additive manufacturing equipment such as the EOS M400 laser powder bed melting system to complete the 3D printing of high-temperature alloy components.

[0042] This embodiment solves the problems of uncontrollable atomization process and excessive oxygen content in the prior art by precisely integrating the telescopic cylinder 121 of the lifting structure 12, the oblique guide design of the sealing ring 111, the rotating connection mechanism of the adjusting nozzle 22 including the arc groove 221 and the connecting ring 131, and the real-time monitoring system of the moving bracket 24 of the camera 23, thus ensuring that the sphericity and purity of the powder are stable and meet the standards.

[0043] The precise control of oxygen content ≤60 ppm is achieved through a dual-barrier mechanism, based on the following theoretical basis: 1. Source isolation barrier The refining chamber was evacuated to ≤10. -2 Pa, thoroughly removes oxygen, water vapor and other oxidizing sources adsorbed in the cavity; High-purity argon gas was introduced to replace the residual gas, reducing the oxygen partial pressure in the cavity to ≤10. -3 Pa is far below the critical oxygen partial pressure for metal oxidation.

[0044] 2. Dynamic sealing barrier The sealing ring features a 304 stainless steel beveled metal protrusion design, maintaining structural integrity even at a high temperature of 1650℃. The clearance fit and oblique guide structure form a "labyrinth seal," and the calculated gas leakage rate is ≤1×10⁻⁶. -6 Pa·m 3 / s, effectively blocking the path for external oxygen to seep in.

[0045] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A high-temperature alloy powder production apparatus for additive manufacturing, comprising a melting structure (1) and an atomizing structure (2), characterized in that: The smelting structure (1) includes a furnace cover (11), a lifting structure (12) is provided on the top of the furnace cover (11), a smelting furnace (13) is provided at the bottom of the furnace cover (11), and an atomizing structure (2) is installed on the smelting furnace (13). The atomizing structure (2) includes a main nozzle (21), which is fixedly connected to the center point of the furnace cover (11). Adjustable nozzles (22) are arranged in a ring around the main nozzle (21). A camera (23) is provided between the smelting furnace (13) and the furnace cover (11). The camera (23) is mounted on a movable bracket (24).

2. The additive manufacturing high-temperature alloy powder production apparatus according to claim 1, characterized in that: The lifting structure (12) consists of two telescopic cylinders (121), which are symmetrically arranged on the central axis of the furnace cover (11).

3. The additive manufacturing high-temperature alloy powder production apparatus according to claim 1, characterized in that: The inner ring of the smelting furnace (13) and the outer ring of the furnace cover (11) are fitted with a clearance, and a sealing ring (111) is provided at the fitting point. The sealing ring (111) is a slanted metal protrusion.

4. The additive manufacturing high-temperature alloy powder production apparatus according to claim 1, characterized in that: The main nozzle (21) is larger than the regulating nozzle (22), and both the main nozzle (21) and the regulating nozzle (22) are connected to the gas tank through pipelines.

5. The additive manufacturing high-temperature alloy powder production apparatus according to claim 1, characterized in that: The adjusting nozzle (22) is rotatably connected to the smelting furnace (13), and a connecting ring (131) is provided at the connection point. An arc-shaped groove (221) is provided at the connection point between the adjusting nozzle (22) and the connecting ring (131).

6. The additive manufacturing high-temperature alloy powder production apparatus according to claim 1, characterized in that: An adjusting arm (222) is fitted on the adjusting nozzle (22). The adjusting arm (222) is a pneumatic adjusting arm and is mounted on the transverse adjusting cylinder (223).

7. The additive manufacturing high-temperature alloy powder production apparatus according to claim 6, characterized in that: The end of the adjusting arm (222) is installed in the adjusting groove (224), the adjusting groove (224) is fixedly connected to the fixing plate (225), and the horizontal adjusting cylinder (223) is installed on the fixing plate (225).

8. The additive manufacturing high-temperature alloy powder production apparatus according to claim 6, characterized in that: A flexible pad (226) is provided at the connection between the adjusting arm (222) and the adjusting nozzle (22).

9. The additive manufacturing high-temperature alloy powder production apparatus according to claim 1, characterized in that: The movable support (24) is a telescopic cylinder, and a camera bracket (241) is installed on the movable support (24). The camera (23) is an industrial high-temperature resistant camera.

10. The method of using the additive manufacturing high-temperature alloy powder production apparatus according to claim 1, characterized in that, The usage steps are as follows: S1. Load the proportioned high-temperature alloy raw materials into the melting furnace (13), close the furnace cover (11), and ensure the airtightness of the melting chamber through the sealing ring; S2. Start the vacuum system to evacuate the melting chamber to ≤10-2Pa, and then introduce inert gas as a protective atmosphere. S3. Start the induction heating system to melt the high-temperature alloy raw material into a uniform liquid metal in the melting furnace (13) and control the melting temperature at 1450-1650℃. S4. Adjust the relative position between the furnace cover (11) and the smelting furnace (13) by means of the lifting structure (12) so that the molten metal surface is at the optimal working height of the atomizing nozzle; S5. Simultaneously open the main nozzle (21) and multiple ring array-arranged regulating nozzles (22), introduce high-pressure inert gas, and perform composite atomization on the molten metal flow from the melting furnace (13) to form atomized spherical droplets. S6. The molten pool status, liquid flow stability and atomization process are monitored in real time by using a camera (23) in conjunction with a mobile support (24). The gas flow rate, angle and position of the main nozzle (21) and the regulating nozzle (22) are dynamically adjusted according to the image feedback. S7. Use the transverse adjustment cylinder (223) to drive the adjustment arm (222), which drives the adjustment nozzle (22) to rotate around the connecting ring (131) to adjust its spray direction and tilt angle, and optimize the atomization cone angle and powder particle size distribution. S8. The atomized droplets cool and solidify in the inert atmosphere protection chamber and fall to the bottom of the furnace to obtain high-temperature alloy powder with a particle size range of 15-105μm, sphericity ≥90%, and oxygen content ≤60ppm.

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